MDR-1000X headband replacement

thingiverse

Sony MDR-1000x is a great headphone, but the only downside is the plastic headband part, which is too weak. My headphones were broken after a year of frequent usage. My wife's headphones lasted a little longer but were broken in the same place. I've designed the replacement parts based on the following design (https://www.thingiverse.com/thing:4946093). The assembly doesn't rely on glue and it is only required to use stock screws that were used in the headphones. It is possible to print parts with no visible supports on the outer surface. The appearance is quite close to a stock design. This design is much more durable than the original one because it uses more material and there is a much bigger surface of contact between the two parts. Slider/folding functionality is preserved. Using this design I was able to repair two headphones. Black headphones were repaired with parts from glass-filled polypropylene-based composite (Novaprint3D). Beige headphones replacement parts were printed from transparent PETG filament (REC3D). I've attached files for parametric modeling (STEP and Fusion 360), in case you want to modify something in the design.